Apparatus and method for connecting two hollow posts in a line

ABSTRACT

An apparatus and method for the rigid connection of two hollow posts (7′, 7″) in a line. The apparatus comprises an expandable load bearing body (4) together with a means for expanding the body laterally in two dimensions within the ends of two hollow posts (7′, 7″). In one embodiment, the expansion means comprise threaded bores (8), set screws (2′, 2″) and contact pads (5) configured to spread the expansive forces within the inside surface of hollow posts (7′, 7″) in two dimensions. Methods for connecting two hollow posts using the apparatus are also described.

CROSS-REFERENCES TO RELATED APPLICATIONS

There are no related patent applications.

FEDERALLY SPONSORED RESEARCH

The invention described herein was not made pursuant to a government agency grant or contract. No government funds were utilized in the described invention.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to an apparatus and method for connecting two hollow members in a line, specifically railing or handrail posts.

Prior Art

A railing is a fencelike barrier with one or more horizontal rails supported by widely spaced upright posts. A handrail is a rail that is designed to be grasped by the hand so as to provide stability or support. Handrails are typically supported by vertical posts or poles mounted directly to walls or floors. Railings and handrails are commonly used near stairways, balconies, and decks in order to prevent injurious falls.

The vertical posts of railings and handrails are often made of metal materials that can corrode and lose their structural integrity. A typical method for fixing handrail posts that have corroded includes: (a) cutting the posts a few inches above the ground; (b) sandblasting the removed posts; (c) coating the removed posts with a powder coat; (d) heating the powder coated posts in an oven; and (e) reconnecting the treated and fixed posts to the original post stumps that were left in step (a).

There are several methods for reconnecting the fixed posts. One common method uses a fishplate, which is a metal plate that is bolted to the ends of the two rail posts or welded to join the two posts back together. However, when the above method is employed to connect two posts, it becomes difficult for the post to be taken apart in case the posts need to be further replaced or fixed. Additionally, the metal fishplate method does not always result in a sufficiently strong and lasting bond and is not aesthetically pleasing.

Another method of reconnecting the posts is by using screws or pins. However, this method also does not always result in a sufficiently strong and lasting bond and pins or screws that are exposed to the outside air can further corrode and lose their structural integrity.

The present invention overcomes the above stated drawbacks by providing an apparatus and method for connecting two hollow posts in a line using expansion forces supplied by a pair of set screws. The proposed invention is simple in design, safer and structurally superior to currently available methods, quick to install, inhibits corrosion, requires minimal alterations to the outsides of the posts, and does not require welding.

Objects and Advantages

One object of the present invention is to provide an apparatus and method for connecting two hollow posts in a line for replacing or fixing railing or handrail posts.

A further object of the invention is to provide an apparatus that provides structurally superior rigid and strong connections for two hollow posts.

A further object of the current invention is to provide an apparatus for connecting two hollow posts that inhibits further corrosion.

A further object of the current invention is to provide an apparatus and method for connecting two hollow posts that is easy to install.

A further object of the current invention is to provide an apparatus and method for connecting two hollow posts that is removable and reusable.

A further object of the current invention is to provide an apparatus and method for connecting two hollow posts that requires minimal alterations to the outside surface of handrail or railing posts.

A further object of the current invention is to provide an apparatus and method for connecting two hollow posts that does not require welding.

Other objectives, advantages, and features of the invention will become more apparent from the disclosure, which includes the above and ongoing written specification and claims, taken in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed for the purpose of illustration only and are not intended as a definition of the limits of the invention.

SUMMARY

In accordance with the invention, an apparatus for connecting two hollow posts in a line comprises an elongated main load bearing body, a means for expanding the main load bearing body, contact pads that serve to redirect the forces along the inside surfaces of the hollow posts, and an optional elastomeric seal which helps align the apparatus body within the posts and prevents moisture from entering the posts.

In the preferred embodiment of the invention, the main load bearing structural body is comprised of two parts. One of these parts is drilled and threaded to accept two set screws which generate the separating force when torque is applied with a hex key wrench. When the set screws are torqued the spreading force is transferred to the contact pads through the structural body. The main structural body has bevelled edges that engage and force apart the contact pads, creating a locking force within the hollow posts. When the contact pads are locked into corresponding sections of appropriately sized posts, the two posts are locked together in an extremely strong and rigid connection. The use of the reversible set screws as the expansion force allows the posts to be locked together and also unlocked at a later time.

An optional elastomeric seal is provided to assist with the alignment of the two posts and to secure the two posts together. The elastomeric seal also acts as a barrier against moisture entering the posts.

While the preferred embodiment shown is designed for elongated posts with a square cross section, the shape of the apparatus and, in particular, the contact pads can be modified to accommodate posts of varying shapes and sizes including tubular posts having a circular cross section.

To use the apparatus, a hole is drilled towards the end of each of the two posts to be connected, one end of the elongated device body is inserted into the drilled end of the first post until the first set screw aligns with the hole made in the first post, the first set screw is rotated until the contact pads within the first post press against the inside surface of the first post, the opposing end of the elongated device body is inserted into the end of the second post until the second set screw aligns with the hole made in the second post, and the second set screw is rotated until the contact pads within the second post press against the inside surface of the second post, connecting the two posts in a strong and rigid manner.

DRAWINGS—FIGURES

In the drawings, closely related figures have the same number but different alphabetic suffixes.

FIG. 1 illustrates in perspective view the fully assembled apparatus of the present invention;

FIG. 2 shows in perspective view from the front of the two parts that form the elongated load bearing body of the present invention;

FIG. 3 illustrates in perspective view the back sides of the two parts shown in FIG. 2 with the set screws inserted into one of the two parts;

FIG. 4A through 4C show three perspective views of the triangular prism shaped contact pad of the present invention;

FIG. 5 illustrates in perspective view the second step of the method for using the apparatus of the present invention with an elastomeric seal whereby one end of the apparatus is inserted into the hollow end of the first post until the first set screw aligns with the hole of the first post and the elastomeric seal is positioned flush against the outside edge of the first post;

FIG. 6 illustrates in perspective view the third step of the method for using the apparatus of the present invention whereby the first set screw is rotated with a wrench;

FIG. 7 illustrates in perspective view the fourth step of the method for using the apparatus whereby a second set screw of the apparatus is aligned with the hole in the second post; and

FIG. 8 shows in perspective view the fifth step of the method for using the apparatus whereby the second set screw is tightened with a wrench until the contact pads within the second post press outward against the inside surface of the second post and create a rigid connection.

DRAWINGS—REFERENCE NUMERALS

 1 - Bevel  2′ - First set screw  2″ - Second set screw  4 - Two-Part main load bearing body  4a - First Part  4b - Second Part  5 - Contact pads  6 - Grooves  7′ - First post  7″ - Second post  8 - Threaded bores 10 - Wrench 11 - O-rings 13 - Elastomeric seal

DETAILED DESCRIPTION—PREFERRED EMBODIMENT—FIGS. 1-4C

A preferred embodiment of the present invention is illustrated in FIG. 1. According to this preferred embodiment, the apparatus is designed to connect hollow posts having a square cross-section. Referring to FIG. 1, this preferred embodiment of the present invention consists of a two-part main load bearing body 4, a pair of set screws 2′ and 2″ which provide an expansion means to expand the two-part main load bearing body 4, eight contact pads 5 (of which six are shown in FIG. 1), which are held in place along the outside of the two-part main load bearing body 4 by four O-rings 11, and an optional elastomeric seal 13.

Two-part main load bearing body 4 supports contact pads 5, which are the points of contact with the insides of the posts being connected. Once the ends of the apparatus are inserted inside the two posts, two-part load bearing body 4 is caused to expand using set screws 2′ and 2″ until contact pads 5 are pressed outwards against the inside surface of the posts.

Referring to FIGS. 2 and 3, main load bearing body 4 shown in FIG. 1 consists of two identical or substantially identical parts 4 a and 4 b. FIG. 2 is a front perspective view of the two parts 4 a and 4 b that form the load bearing body 4 of the present invention. First part 4 a contains two drilled and threaded bores 8 that accept first and second set screws 2′ and 2″ (shown in FIG. 3). Two of the edges on the front side of both parts 4 a and 4 b contain a bevel 1.

The means for expanding the main load bearing body shown in FIG. 1 is through the use of set screws 2′ and 2″. FIG. 3 illustrates in perspective view the back sides of first and second parts 4 a and 4 b with set screws 2′ and 2″ inserted. A set screw is a type of screw that is fully threaded and has no head extending laterally past the major diameter of the screw. Set screws are often driven with an internal-wrenching drive, such as a hex socket (Allen), star (Torx), square socket (Robertson), or slot. Set screws 2′ and 2″ are screwed into threaded bores 8 from the front of part 4 a shown in FIG. 2.

In a preferred embodiment, the apparatus has eight contact pads 5 each of which exhibit a triangular prism shape. FIGS. 4A through 4C illustrate each of the three rectangular faces of each contact pad 5. Two of the rectangular faces of the triangular prism contact pads 5 have two grooves 6 running perpendicular to the length of contact pads 5. Grooves 6 receive O-rings 11 (shown in FIG. 1).

To assemble the apparatus shown in FIG. 1, set screws 2′ and 2″ are screwed into threaded bores 8 from the front side of first part 4 a shown in FIG. 2. First and second parts 4 a and 4 b are placed together such that the front sides of parts 4 a and 4 b with the four bevelled edges 1 (shown in FIG. 2) face outwards and the back sides of part 4 a and 4 b (shown in FIG. 3) lie adjacent to each other. Set screws 2′ and 2″ are oriented perpendicular to the adjacent back surfaces of first and second parts 4 a and 4 b. Two contact pads 5 are placed on each of the two bevels 1 on each part 4 a and 4 b of body 4 (eight contact pads 5 in all) such that grooves 6 of contact pads 5 face outwards. Contact pads 5 are elastically held in place along main load bearing body 4 by four rubber O-rings 11 that fit within grooves 6 of contact pads 5.

An optional elastomeric seal 13 is placed in the middle of the apparatus such that half of the two-part main load bearing body 4, one set screw 2′ or 2″, and four of the eight contact pads 5 are on each side of elastomeric seal 13. The optional elastomeric seal 13 is provided to better align and additionally secure the posts being connected in line, as well as act as a barrier to prevent moisture from entering the posts once the posts are connected using the apparatus.

When torque is applied to set screws 2′ and 2″ using a wrench (shown in FIG. 6), the rotational forces within threaded bores 8 push set screws 2′ and 2″ through first part 4 a. As set screws 2′ and 2″ move through and protrude beyond the outside surface of said part 4 a, set screws 2′ and 2″ abut against second part 4 b and push second part 4 b away from first part 4 a laterally in two dimensions. As set screws 2′ and 2″ push part 4 b away from part 4 a, bevelled edges 1 of parts 4 a and 4 b engage with and force apart contact pads 5, transferring the spreading force to contact pads 5. Set screws 2′ and 2″ are rotated until contact pads 5 engage with inside surfaces of the posts (not shown) creating a strong and rigid locking force within the inside of the posts being connected.

Due to the configuration of contact pads 5 relative to bevel 1, the lateral forces being directed by set screws 2′ and 2″ in one direction are transformed such that each contact pad 5 exerts a force upon the inside surfaces of the posts in two dimensions, each force being lateral to the length of the posts.

In the preferred embodiment shown in FIG. 1, the apparatus is designed to connect two posts that have a square cross-section. In this embodiment, when in the locked position, apex of contact pads 5 lies against the inside corners of the posts and exerts a lateral force against all four inside surfaces—top, bottom, and two sides—of the posts. When contact pads 5 are locked into corresponding sections of appropriately sized posts, the two posts are locked together in an extremely strong and rigid connection.

While the preferred embodiments shown in FIGS. 1-4C are designed for hollow posts with square cross-sections, with first and second parts 4 a and 4 b are elongated body elements having a rectangular cross-section and each of the eight contact pads 5 are prism shape demonstrating a triangular cross-section, the shape of the apparatus can be modified to accommodate hollow posts of varying shapes and sizes. For example, to accommodate a hollow post with a circular cross-section, contact pads 5 could be modified to be semi-circular in cross section in order to demonstrate a curved outside surface that would engage the curved inside surface of the hollow post.

To prevent corrosion to the apparatus, the apparatus may be coated in a protective coating or corrosion inhibitor material such as Cosmoline.

In the preferred embodiment, the apparatus is made with a rigid material such as steel, hard plastic, wood, or other metals. The contact pads 5 and elastomeric seal 13 can, alternatively, be fabricated using materials different from the materials used to make parts 4 a and 4 b, such as, but not limited to, rubber, silicone, hard plastics, and other materials. In addition, the invention also anticipates expanding the load bearing body other than as illustrated. By way of example, and not limitation, the load bearing body can be made of more then two parts, and can be expanded through means other than the use of set screws 2′ and 2″, as for example, a pair of compression springs.

In addition, the load bearing body can exert lateral expansive forces outwards against the inside of the posts to be connected directed 90 degrees one from the other, or some angle between 0 and 90 degrees one from the other, or a plurality of lateral forces that are directed at a variety of angles between 0 and 90 degrees one from the other.

OPERATION—PREFERRED EMBODIMENT—FIGS. 5-8

A preferred embodiment of the method of the present invention for using the apparatus for connecting two posts together in a straight line is illustrated with respect to FIGS. 5 through 8 and involves one or more of the following steps. First, a hole is drilled a certain distance from the end of each of the two posts 7′ and 7″. The distance between the hole and the end of first post 7′ is equal to the distance between the edge of elastomeric seal 13 and first set screw 2′ on the apparatus or, if no elastomeric seal 13 is used, the distance should be no more than the distance between the middle of the apparatus and first set screw 2′. The distance between the hole and the end of second post 7″ is equal to the distance between the edge of elastomeric seal 13 and second set screw 2″ on the apparatus or, if no elastomeric seal is used, the distance should be no more than the distance between the middle of the apparatus and second set screw 2″.

In the second step, as illustrated in FIG. 5, one half of the apparatus is inserted into the end of first post 7′ such that elastomeric seal 13 is flush with the edge of post 7′ and the hole in post 7′ aligns with first set screw 2′ of the apparatus. If no elastomeric seal 13 is used, then the apparatus is inserted into the end of first post 7′ until the hole in post 7′ aligns with first set screw 2′ of the apparatus.

In the third step, as shown in FIG. 6, first set screw 2′ (not shown) is rotated by inserting a wrench 10 through the hole in first post 7′ and into first set screw 2′ (not shown). As set screw 2′ is rotated, set screw 2′ pushes part 4 a and 4 b apart until contact pads 5 (not shown) within first post 7′ press outward against the inside surface of post 7′.

In the fourth step, the second half of the apparatus is inserted into the end of second post 7″ such that elastomeric seal 13 is flush with the edge of post 7″ and the hole of second post 7″ aligns with second set screw 2″ of the apparatus. If no elastomeric seal 13 is used, as shown in FIG. 7, then the second half of the apparatus is inserted into the end of second post 7″ until the edge of second post 7″ is flush with the edge of first post 7′ and the hole in post 7″ aligns with second set screw 2″ of the apparatus.

In the fifth step, as illustrated in FIG. 8, second set screw 2″ (not shown) is rotated by inserting wrench 10 through the hole in second post 7″ and into second set screw 2″ (not shown). As set screw 2″ (not shown) is rotated, set screw 2″ pushes parts 4 a and 4 b (not shown) inside post 7″ apart until contact pads 5 (not shown) within second post 7″ press outward against the inside surface of post 7″.

As an optional sixth step, first set screw 2′ may need to be further rotated by wrench 10 through the hole in first post 7′ to ensure that the in line connection between posts 7′ and 7″ is rigid and secure.

As an optional final step, a rubber seal or plug is inserted into the holes of the two posts after the apparatus is installed to help prevent moisture from seeping in.

In addition, the order of the steps illustrated in FIGS. 5 through 8 and described above may be modified without departing from the scope of spirit of the invention. By way of example and not limitation, steps three and four can be modified such that the user places the apparatus into posts 7′ and 7″ before rotating set screws 2′ and 2″ with wrench 10.

CONCLUSION, RAMIFICATIONS, AND SCOPE

Unless otherwise indicated, all numbers, dimension, materials and so forth used in the specification and claims are to be understood as being examples and not limitations, and in any event, not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims.

The terms “a,” “an,” “the,” and similar references used in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language provided herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of any claim. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

Certain embodiments are described herein, including the best mode known to the inventor for carrying out the invention. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventor intends for the invention to be practiced otherwise than specifically described herein.

Accordingly, the claims include all modifications and equivalents of the subject matter recited in the claims as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is contemplated, and method steps may be performed in any order, unless otherwise indicated herein or otherwise clearly contradicted by context.

While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. For example, alternative means for expanding load bearing body 4, and alternative means for spreading the expansive forces across the cross-section of the inside of posts 7′ and 7″, will be obvious to those skilled in the art and such alternative means are encompassed within the subject invention. Similarly, means for accessing set screws 2 through posts 7′ and 7″ other than holes are contemplated, as are alternative embodiments of load bearing body 4 and contact pads 5 sized and shaped to accommodate railing posts of varying configurations. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.

In closing, it is to be understood that the embodiments disclosed herein are illustrative of the principles of the claims. Other modifications that may be employed are within the scope of the claims. Thus, by way of example, but not of limitation, alternative embodiments may be utilized in accordance with the teachings herein. Accordingly, the claims are not limited to embodiments precisely as shown and described. 

I claim:
 1. An apparatus for in-line connection of hollow posts with walls comprising: a. an expandable elongated load bearing body sized to fit snugly within an end of said hollow posts; and b. a means for expanding said load bearing body laterally against the inside walls of said hollow posts when said body is inserted into said hollow posts.
 2. The apparatus of claim 1, wherein said elongated load bearing body expands laterally in two dimensions.
 3. The apparatus of claim 1, wherein said elongated load bearing body expands substantially simultaneously, and with equal force, against the top, bottom, and both sides of the inside walls of said hollow posts.
 4. The apparatus of claim 1, wherein said elongated load bearing body comprises a first and second elongated portion that lie adjacent to one another, the first said portion drilled and tapped with at least two holes oriented laterally and with set screws received within each said hole such that, when said set screws are screwed from the outside inward to protrude beyond said first body portion, said set screws exert an opposing force on the inward facing surface of said second body portion expanding said elongated load bearing body laterally.
 5. The apparatus of claim 4, wherein said elongated body further comprises elongated contact elements that lie lengthwise along the outside surfaces of said load bearing body and that function to redirect the lateral expansive force exerted by said load bearing body to the inside walls of said hollow posts in two dimensions.
 6. The apparatus of claim 5 wherein said apparatus is used to connect rectangular posts in line and said contact elements are triangular in cross section such that, when said apparatus is inserted into the end of said posts, the apex of said triangular contact elements lies against the inside corners of said posts.
 7. The apparatus of claim 5 wherein said apparatus is used to connect round posts in line and said contact elements are semi-circular in cross section such that, when said apparatus is inserted into the end of said posts, the rounded surface of said rounded contact elements lies against the rounded inside walls of said posts.
 8. The apparatus of claim 4 wherein the means for expanding said load bearing body when said load bearing body is inserted within said hollow posts comprises one or more holes drilled through the ends of said post walls allowing access to said set screws, and a wrench inserted into said holes is used to tighten said set screws.
 9. The apparatus of claim 1 further comprising one or more elastomeric cinctures encircling the narrow portion of said load bearing body to provide a moisture barrier when said load bearing body is inserted into and secured within said post ends.
 10. A method for in-line connection of hollow posts with walls comprising: a. providing a connector having an expandable elongated load bearing body sized to fit snugly within an end of said hollow posts having a means for expanding said load bearing body laterally; b. forming an access means within the walls of the ends of two available hollow posts that permits access to the connector after the connector has been inserted into said post end; c. inserting one end of said expandable connector into the end of the first available hollow post; d. inserting the opposing end of said expandable connector into the end of the second hollow post; and e. activating the expanding means of said connector through said access means such that said expandable connector presses firmly outwards against the inside walls of said hollow posts, whereby said two hollow posts will be connected firmly and securely in a line.
 11. The method for in-line connection of hollow posts of claim 10, wherein said connector expands laterally against the inside walls of said hollow posts in two dimensions.
 12. The method for in-line connection of hollow posts of claim 10, wherein said connector expands substantially simultaneously against the top, bottom, and both sides of the inside walls of said hollow posts.
 13. The method for in-line connection of hollow posts of claim 10, wherein said method is used to connect rectangular posts and said connector further comprises contact elements triangular in cross section that lie outside said load bearing body positioned such that, when said connector is inserted into the end of said post and expanded, the apex of said triangular contact elements lies against the inside corners of said posts and serves to redirect the expansive forces of said connector to said inside corners in two directions.
 14. The method for in-line connection of hollow posts of claim 10, wherein said method is used to connect round posts and said connector further comprises contact elements semi-circular in cross section that lie outside said load bearing body positioned such that, when said connector is inserted into the end of said post, the curved surface of said semi-circular contact elements lies against the rounded inside walls of said posts and serves to redirect the expansive forces of said connector to said inside surface in two directions.
 15. A method for in-line connection of hollow posts with walls comprising, providing a connector having an expandable elongated load bearing body sized to fit snugly within an end of said hollow posts and a means for expanding said load bearing body laterally, and instructing the user to perform one or more of the following steps: a. form an access means within the walls of the ends of two available hollow posts; b. insert one end of said connector into the end of said first available hollow post; c. insert the opposing end of said connector into the end of said second hollow post; and d. activate the expanding means of said connector through said access means such that said connector presses firmly outwards against the inside walls of said hollow posts, whereby said two hollow posts will be connected firmly and securely in a line.
 16. The method for in-line connection of hollow posts of claim 15, wherein said connector expands laterally against the inside walls of said hollow posts in two dimensions.
 17. The method for in-line connection of hollow posts of claim 15, wherein said connector expands substantially simultaneously against the top, bottom, and both sides of the inside walls of said hollow posts.
 18. A system for in-line connection of hollow posts with walls comprising: a. a connector having an expandable elongated load bearing body sized to fit snugly within an end of said hollow post and means for expanding said load bearing body laterally in two dimensions against the inside walls of said hollow posts when said body is inserted inside said hollow posts; and b. hollow posts with access means formed in the ends thereof to allow access to the expansion means of said connector when said connector is fitted within said posts.
 19. The system of claim 18, wherein said connector expands substantially simultaneously against the top, bottom, and both sides of the inside walls of said hollow posts.
 20. The system of claim 18, wherein said system is used to connect rectangular posts in line and said expandable load bearing body includes contact elements triangular in cross section that extend out from each corner of said body such that, when said apparatus is inserted into the end of said posts, the apex of said triangular contact elements lies against the inside corners of said posts. 